CN114044442B - Grab ship unloader control system and grab ship unloader control method - Google Patents
Grab ship unloader control system and grab ship unloader control method Download PDFInfo
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- CN114044442B CN114044442B CN202111416038.3A CN202111416038A CN114044442B CN 114044442 B CN114044442 B CN 114044442B CN 202111416038 A CN202111416038 A CN 202111416038A CN 114044442 B CN114044442 B CN 114044442B
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- ship unloader
- wire rope
- grab ship
- steel wire
- rope
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/16—Applications of indicating, registering, or weighing devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/40—Applications of devices for transmitting control pulses; Applications of remote control devices
- B66C13/44—Electrical transmitters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/48—Automatic control of crane drives for producing a single or repeated working cycle; Programme control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C13/00—Other constructional features or details
- B66C13/18—Control systems or devices
- B66C13/50—Applications of limit circuits or of limit-switch arrangements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
- B66C15/04—Safety gear for preventing collisions, e.g. between cranes or trolleys operating on the same track
- B66C15/045—Safety gear for preventing collisions, e.g. between cranes or trolleys operating on the same track electrical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C15/00—Safety gear
- B66C15/06—Arrangements or use of warning devices
- B66C15/065—Arrangements or use of warning devices electrical
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B66—HOISTING; LIFTING; HAULING
- B66C—CRANES; LOAD-ENGAGING ELEMENTS OR DEVICES FOR CRANES, CAPSTANS, WINCHES, OR TACKLES
- B66C23/00—Cranes comprising essentially a beam, boom, or triangular structure acting as a cantilever and mounted for translatory of swinging movements in vertical or horizontal planes or a combination of such movements, e.g. jib-cranes, derricks, tower cranes
- B66C23/88—Safety gear
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Automation & Control Theory (AREA)
- Ship Loading And Unloading (AREA)
Abstract
The invention provides a grab ship unloader control system and a grab ship unloader control method. The control system is arranged on the grab ship unloader main body mechanism and mainly comprises: the system comprises a lifting opening and closing mechanism rope breakage detection subsystem, a traction steel wire rope breakage detection subsystem, a grab ship unloader anti-collision subsystem and a control system; the lifting switching mechanism rope breakage detection subsystem, the traction steel wire rope breakage detection subsystem and the grab ship unloader anti-collision subsystem are connected with the control system through signals, and the control system controls the actuating mechanism of the grab ship unloader to act. The invention provides a high-reliability grab ship unloader, which improves the operation stability to the maximum extent.
Description
Technical Field
The invention relates to bulk cargo wharf grab ship unloader equipment, in particular to a grab ship unloader control system and method.
Background
The reliability of the grab ship unloader is a key for determining the operation efficiency of the bulk cargo wharf, and once the grab ship unloader fails to stop, the whole bulk cargo conveying line of the wharf is greatly influenced. Accidents such as rope breakage of the steel wire rope and collision of the ship unloader can cause long-time fault shutdown of equipment, and once the accidents occur, a large amount of operation cost is increased for the wharf.
Disclosure of Invention
The invention provides a grab ship unloader control system and a grab ship unloader control method.
The invention adopts the following technical means:
a grab ship unloader control system disposed on a grab ship unloader body mechanism, comprising: the system comprises a rope breakage detection subsystem, a grab ship unloader anti-collision subsystem and a control system, wherein the rope breakage detection subsystem comprises a lifting opening and closing mechanism rope breakage detection subsystem and a traction steel wire rope breakage detection subsystem;
the lifting switching mechanism rope breakage detection subsystem is in signal connection with a first detection port of the control system through a bus network and is used for sending a lifting switching mechanism rope breakage detection signal to the control system;
the traction steel wire rope breakage detection subsystem is in signal connection with a second detection port of the control system through a bus network and is used for sending a traction steel wire rope breakage detection signal to the control system;
the grab ship unloader anti-collision subsystem is in signal connection with a third detection port of the control system through a bus network and is used for sending a grab ship unloader anti-collision detection signal to the control system;
The control port of the control system is connected with the executing mechanism of the grab ship unloader and is used for controlling the executing mechanism to act according to the received rope breakage detection signal of the lifting opening and closing mechanism, the rope breakage detection signal of the traction steel wire rope and the anti-collision detection signal of the grab ship unloader.
Further, the lifting opening and closing mechanism rope breakage detection subsystem comprises:
the steel wire rope state detection unit is arranged in the main trolley area of the grab ship unloader and is used for detecting whether the lifting and opening steel wire rope runs in the pulley groove or not and the running rotating speed of a main pulley on the trolley in real time;
the winding drum running state detection unit is arranged at the end part of the lifting and opening-closing winding drum in the machine room and is used for detecting the running rotating speed of the steel wire rope winding drum;
the wire rope state detection unit and the winding drum running state detection unit are respectively connected with the PLC control unit of the control system through buses, and the PLC control unit gives out a rope breakage fault alarm according to state data detected by the wire rope state detection unit and the winding drum running state detection unit and controls the action of the execution unit.
Further, the steel wire rope state detection unit comprises an ultrasonic sensor, an RFID detection device, a coding disc, a communication module, a DI module, a wireless transmission device and a storage battery;
The ultrasonic sensor is arranged at a main pulley rope groove on the main trolley frame and used for detecting whether the lifting and opening-closing steel wire rope runs in the pulley rope groove or not;
the RFID detection device is arranged on the side wall of the main pulley on the main trolley frame, the coding disc of the RFID detection device is arranged around the side wall of the main pulley, and the RFID detection device is used for measuring the rotating speed of the main pulley by reading the data of the coding disc during the rotation process of the main pulley;
the communication module is arranged in an electric cabinet on the main trolley frame and is used for receiving the measured data of the RFID detection device;
the DI module is arranged in an electric cabinet on the main trolley frame and is used for receiving the data of the ultrasonic sensor;
the wireless transmission device is arranged in an electric cabinet on the main trolley frame and is used for realizing data communication with the PLC control unit;
the storage battery is arranged in an electric cabinet on the main trolley frame.
Further, the traction steel wire rope breakage detection subsystem comprises a traction steel wire rope state detection unit which is arranged at the end part of the arm frame of the grab ship unloader and in a rear girder area, and the traction steel wire rope state detection unit is used for detecting the running state of the traction steel wire rope of the trolley in real time and specifically comprises two detection nodes which are arranged at the end part of the arm frame of the grab ship unloader and in the rear girder area;
The detection node comprises a limit switch, a communication module, a DI module and a broken rope detection stop block;
the method comprises the steps that a rail for running the grab ship unloader trolley is paved on a grab ship unloader arm frame, a sea side rope supporting trolley, a main trolley and a land side rope supporting trolley are sequentially arranged on the rail, a traction steel wire rope is fixed on two sides of the main trolley and is rotationally fixed to the front end and the rear end of the grab ship unloader arm frame respectively through the sea side rope supporting trolley and the land side rope supporting trolley, a rope breakage detection stop block is arranged in the middle of a rotation section of the steel wire rope, limit switches are arranged at two ends of the rotation section, and after the limit switch signals are connected into a DI module, the limit switch signals are sent to a PLC control unit of a control system through a communication module;
in the process of monitoring the state signal of the limit switch in the traction steel wire rope breakage detection unit in real time, once the change of the limit switch signal is found, the PLC control unit judges that the traction steel wire rope breakage causes the limit switch to act, immediately sends out rope breakage fault alarm, and controls the execution unit to act.
Further, the grapple ship unloader anti-collision subsystem includes:
the space positioning unit is arranged in the tower head area of the grab ship unloader, the space positioning unit obtains the whole machine positioning information of the grab ship unloader based on the Beidou space positioning technology, and the space positioning unit comprises an antenna and a data receiver which are arranged in the tower head area of the grab ship unloader;
The mechanism positioning unit is arranged on each focusing mechanism of the grab ship unloader and used for acquiring positioning information of each mechanism of the grab ship unloader, and comprises an arm support pitching angle positioning device arranged at an arm support twisting point, a cab displacement positioning device arranged at the top of a cab and a grab bucket position positioning device arranged in a machine room;
the PLC control unit establishes a space three-dimensional coordinate system according to the whole machine positioning information of the grab ship unloader, and meanwhile adds the focus mechanism positioning information of the grab ship unloader into the space three-dimensional coordinate system so as to perform collision early warning and control the action of the executing mechanism.
Further, the arm support pitching angle positioning device is an inclinometer and is used for detecting the pitching operation angle of the arm support and sending the pitching operation angle to the PLC;
the cab displacement positioning device is a cab absolute value encoder and is used for acquiring cab positioning data and sending the cab positioning data to the PLC;
the grab bucket position positioning device comprises a lifting absolute value encoder and a trolley absolute value encoder, wherein the lifting absolute value encoder is used for acquiring grab bucket lifting data and sending the grab bucket lifting data to the PLC control unit, and the trolley absolute value encoder is used for acquiring trolley mechanism positioning data and sending the trolley mechanism positioning data to the PLC control unit.
The invention also discloses a grab ship unloader control method, which is realized based on the grab ship unloader control system described in any one of the above, and comprises the following steps:
the control system is used for acquiring a rope breakage detection signal of the lifting opening and closing mechanism and carrying out rope breakage control of the lifting opening and closing mechanism according to the detection signal;
acquiring a traction steel wire rope breakage detection signal based on the control system, and performing traction steel wire rope breakage control according to the detection signal;
and acquiring an anti-collision detection signal of the grab ship unloader based on the control system, and carrying out anti-collision control of the grab ship unloader according to the detection signal.
Further, based on the control system obtains the detection signal of rope breakage of the lifting opening and closing mechanism, and carries out rope breakage control of the lifting opening and closing mechanism according to the detection signal, comprising:
the PLC control unit detects four groups of ultrasonic sensor signals in the wire rope breakage detection unit in real time, when any group of ultrasonic sensor signals change, the wire rope is judged to be broken, the wire rope is pulled out, a rope breakage fault alarm is immediately sent out, and the operation of a corresponding main mechanism is timely interrupted;
the PLC control unit receives real-time data of four groups of RFID detection devices in the steel wire rope state detection unit and four groups of absolute value encoders in the winding drum running state detection unit simultaneously, converts and compares the data of the four groups of RFID detection devices and the data of the four groups of absolute value encoders, and once the ratio of the running speed of the main pulley fed back by the RFID to the running speed of the winding drum fed back by the absolute value encoder is lower than a set threshold value, the phenomenon that the steel wire rope breaks is judged, a rope breaking fault alarm is immediately sent out, and the running of a corresponding main mechanism is timely interrupted.
Further, based on the control system, obtain the disconnected rope detection signal of traction wire rope to carry out the disconnected rope control of traction wire rope according to the detected signal, include:
in the process of monitoring the state signal of the limit switch in the traction steel wire rope breakage detection unit in real time, once the change of the limit switch signal is found, the PLC control unit judges that the traction steel wire rope breakage causes the limit switch to act, immediately sends out rope breakage fault warning, and timely interrupts the operation of a corresponding mechanism.
Further, based on the control system obtains grab ship unloader anticollision detection signal to carry out grab ship unloader anticollision control according to the detection signal, include:
the method comprises the steps that based on the PLC control unit, the whole grab ship unloader positioning information output by the space positioning unit is obtained, a space three-dimensional coordinate system is established based on the whole grab ship unloader positioning information, an X axis of the space three-dimensional coordinate system extends along the horizontal direction of a cart track, a Y axis extends along the horizontal direction of a vertical cart track, and a Z axis extends along the vertical direction;
based on the PLC control unit, positioning information of each mechanism of the grab ship unloader is obtained, a grab ship unloader space model is built by combining the actual size of the grab ship unloader, and the grab ship unloader space model is fused into the space three-dimensional coordinate system;
Acquiring data information of space positions of adjacent equipment and ships through a wharf central control system and integrating the data information into the space three-dimensional coordinate system;
and carrying out collision prompt based on the whole grab ship unloader positioning information, the grab ship unloader space model, the adjacent equipment and the ship space position data information in the space three-dimensional coordinate system, and controlling the action of an executing mechanism.
Compared with the prior art, the invention has the following advantages:
1. the invention is applied to bulk cargo wharf grab ship unloader equipment, and detects the running states of the lifting and opening and closing steel wire ropes in a mode of configuring an ultrasonic sensor, an RFID detection device and an encoder, and once the rope breakage fault occurs, the detection system sends out a fault alarm signal, so that the functions of lifting the grab ship unloader and detecting the rope breakage of an opening and closing mechanism are realized.
2. According to the invention, the running state of the trolley traction steel wire rope is detected by arranging the rope breakage detection devices at the end part of the arm support and the position of the rear girder in the trolley traction steel wire rope system, so that the function of detecting the rope breakage fault of the trolley traction steel wire rope of the grab ship unloader is realized.
3. The invention realizes the integral anti-collision protection of the grab ship unloader by adopting the space positioning technology, has no detection blind spot and has high safety and reliability. Meanwhile, the technology can be combined with the conventional anti-collision protection technology based on detection means such as limit switches, laser ranging, millimeter wave radar and the like, so that redundant protection on control is formed, and the operation safety and reliability of the grab ship unloader are further enhanced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to the drawings without inventive effort to a person skilled in the art.
FIG. 1 is a schematic diagram of the control system of the grab ship unloader of the present invention.
Fig. 2 is a schematic diagram of a rope breakage detecting subsystem of a lifting opening and closing mechanism of the invention.
Fig. 3 is a schematic diagram of a rope breakage detection subsystem of a traction steel wire rope of a grab ship unloader trolley.
Fig. 4 is a schematic view of the anti-collision subsystem of the grab ship unloader.
Fig. 5 is a layout diagram of a rope breakage detection subsystem device of a lifting opening and closing mechanism in an embodiment.
Fig. 6a is a layout diagram of a device of a rope breakage detection subsystem of a grab ship unloader trolley traction wire rope in an embodiment.
Fig. 6b is a schematic diagram of a rope wrap of a rope breakage detection subsystem of a grab ship unloader trolley traction rope in an embodiment.
Fig. 6c is a schematic diagram of a limit switch arrangement at a rotation position of a rope at the front end of an arm support of a traction steel wire rope breakage detection subsystem of a grab ship unloader trolley in an embodiment.
Fig. 7a is a diagram of an antenna arrangement for a grapple ship unloader crash subsystem in an embodiment.
Fig. 7b is a schematic diagram of an arrangement of a grapple ship unloader collision avoidance subsystem device in an embodiment.
Fig. 7c is a schematic diagram of the construction of a three-dimensional coordinate system of the anti-collision subsystem of the grab ship unloader in an embodiment.
FIG. 8 is a flow chart of a method of controlling a grapple ship unloader of the present invention.
In the figure: 1. a control system; 201. a wire rope state detection unit; 202. a spool running state detection unit; 3. a traction wire rope state detection unit; 401. a mechanism positioning unit; 402. a space positioning unit; a01, opening and closing the steel wire rope 1; a02, lifting a steel wire rope 1; a03, opening and closing a pulley; a04, lifting pulleys; a05, an ultrasonic sensor; a06, a main trolley; a07, opening and closing a steel wire rope 2; a08, lifting the steel wire rope 2; a09, electric cabinet; a10, an RFID detection device and an encoder; a11, opening and closing a winding drum in a machine room; a12, lifting a winding drum of the machine room; a13, an absolute value encoder; a14, grab bucket.
Detailed Description
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments. For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. The following description of at least one exemplary embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
As shown in fig. 1, the present invention provides a control system for a grab ship unloader, which is provided on a main body mechanism of the grab ship unloader, comprising: the rope breakage detection subsystem comprises a lifting opening and closing mechanism rope breakage detection subsystem and a traction steel wire rope breakage detection subsystem. The lifting switching mechanism rope breakage detection subsystem is in signal connection with a first detection port of the control system through a bus network and is used for sending a lifting switching mechanism rope breakage detection signal to the control system. The traction steel wire rope breakage detection subsystem is in signal connection with a second detection port of the control system through a bus network and is used for sending a traction steel wire rope breakage detection signal to the control system. The grab ship unloader anti-collision subsystem is in signal connection with a third detection port of the control system through a bus network and is used for sending an anti-collision detection signal of the grab ship unloader to the control system. The control port of the control system is connected with the executing mechanism of the grab ship unloader and is used for controlling the executing mechanism to act according to the received rope breakage detection signal of the lifting opening and closing mechanism, the rope breakage detection signal of the traction steel wire rope and the anti-collision detection signal of the grab ship unloader. The executing mechanism comprises a frequency converter, a motor, a brake and the like, is controlled by a control system and is used for executing the whole operation action of the grab ship unloader. The system of the invention can also comprise an alarm module, wherein the alarm module is connected with a control port of the control unit, and when the PLC control unit judges that the rope is broken or collision occurs, an instruction is sent to control the alarm module to send an alarm signal. Preferably, the alarm signal can be directly transmitted through an acoustic or optical alarm device, or can be sent to a remote monitoring system through a communication means.
The control system mainly comprises a PLC control unit and a communication unit, wherein the communication unit comprises an Ethernet communication module, a DP communication module, a wireless transmission module and the like. The lifting opening and closing mechanism rope breakage detection subsystem, the traction steel wire rope breakage detection subsystem and the grab ship unloader anti-collision subsystem are respectively connected with the control system through different communication modules so as to realize detection control functions.
Preferably, the rope breakage detection subsystem of the grab ship unloader lifting opening and closing mechanism consists of a steel wire rope state detection unit and a winding drum running state detection unit, and the steel wire rope state detection unit and the winding drum running state detection unit are respectively in communication connection with a PLC control unit in the control system. The steel wire rope state detection unit is arranged in the grab ship unloader main trolley area and is used for detecting the operation state of the lifting and opening and closing steel wire rope and the operation state of the main pulley on the trolley in real time, namely detecting the operation of the lifting and opening and closing steel wire rope in the pulley groove in real time and detecting the operation rotating speed of the main pulley. The drum running state detection unit is arranged at the end part of the lifting and opening/closing drum in the machine room and is used for detecting the running state of the steel wire rope drum, namely detecting the running rotating speed of the drum. The PLC control unit is arranged in the PLC room and used for collecting data and carrying out algorithm analysis and timely giving out rope breakage fault warning.
Further, as shown in fig. 2, the wire rope state detection unit is composed of an ultrasonic sensor, an RFID detection device, a code disc, a communication module, a DI module, a wireless transmission device and a storage battery. The drum running state detection unit consists of four groups of absolute value encoders and mounting brackets thereof. The steel wire rope state detection unit, the winding drum running state detection unit and the PLC control unit are connected through a Profibus DP bus.
In a specific embodiment of the invention, the arrangement position of the rope breakage detection subsystem device of the lifting opening and closing mechanism is shown in fig. 5. The ultrasonic sensor is arranged near the main pulley rope groove on the main trolley frame and is used for detecting whether the lifting and opening/closing steel wire rope runs in the pulley rope groove or not. The RFID detection device is arranged near the side wall of the main pulley on the main trolley frame, the coding disc of the RFID detection device is arranged around the side wall of the main pulley in a circle, and the RFID detection device is used for measuring the rotating speed of the main pulley by reading the data of the coding disc in the rotating process of the main pulley. In addition, the communication module is arranged in an electric cabinet on the main trolley frame and is used for receiving the data of the RFID detection device. The DI module is arranged in an electric cabinet on the main trolley frame and is used for receiving the data of the ultrasonic sensor. The wireless transmission device is arranged in an electric cabinet on the main trolley frame and used for realizing data communication with the main PLC control unit. The storage battery is arranged in an electric cabinet on the main trolley frame and is used for supplying power to the electric elements.
Preferably, the rope breakage detection subsystem of the grab ship unloader trolley traction steel wire rope mainly comprises a traction steel wire rope state detection unit, and the traction steel wire rope state detection unit is connected with the PLC control unit through a Profibus DP bus. The traction steel wire rope state detection unit is used for detecting the running state of the trolley traction steel wire rope in real time and comprises two detection nodes arranged at the end part of the grab ship unloader arm frame and in a rear girder area, and the detection nodes comprise a limit switch, a first communication module, a DI module and a rope breakage detection stop block, as shown in fig. 3.
In a specific embodiment of the invention, the arrangement positions of the rope breakage detection subsystem devices of the lifting opening and closing mechanism are shown in fig. 6a-6c, two sea side rope supporting trolleys, a main trolley and two land side rope supporting trolleys are sequentially arranged on the running track of the grab ship unloader trolley paved on the grab ship unloader arm frame, a traction steel wire rope is fixed on two sides of the main trolley and is rotationally fixed to the front end and the rear end of the grab ship unloader arm frame respectively through the land side rope supporting trolleys of the sea side rope supporting trolleys, the rope breakage detection stop block is arranged in the middle of a rotation section of the steel wire rope, limit switches are arranged at two end parts of the rotation section, and after the limit switch signals are connected to the DI module, the DI module is transmitted to the control unit through the first communication module.
Specifically, the rope supporting trolley is used for supporting the lifting main steel wire rope for opening and closing, and excessive loosening of the main steel wire rope is avoided. The number of the rope supporting trolleys influences the winding mode of the trolley traction steel wire ropes, but basically does not influence the design of a rope breakage detection scheme. For example, in the four-rope-supporting trolley in this embodiment, 2 steel wire ropes are formed at the front end and the rear end of the arm support respectively by winding the trolley traction steel wire ropes, and 4 groups of detection devices are correspondingly configured. In the embodiment adopting the two rope supporting trolleys, if 1 sea side rope supporting trolley and 1 land side rope supporting trolley are adopted, the winding of the trolley traction steel wire rope can respectively form 1 steel wire rope at the front end and the rear end of the arm frame, and 2 groups of detection devices are correspondingly configured. But the mounting design of each set of detection devices is the same.
Taking a grab ship unloader in the form of a four-rope trolley in the embodiment as an example, a rope system for forming a trolley traction steel wire rope is formed by six traction steel wire ropes. A first steel wire rope: the starting position is the left fixed end of the sea side of the first rope supporting trolley at sea side, the left fixed end is folded back through a pulley fixed at the left side of the front end of the arm support, the left pulley fixed at the tensioning device at the rear end of the arm support is folded back again, and the ending position is the left fixed end of the land side of the second rope supporting trolley at land side. And a second steel wire rope: the starting position is the right fixed end of the sea side surface of the first rope supporting trolley at sea side, the right fixed end is folded back through a pulley fixed on the right side of the front end of the arm support, the right pulley fixed at the tensioning device at the rear end of the arm support is folded back again, and the ending position is the right fixed end of the land side surface of the second rope supporting trolley at land side. Third wire rope: the starting position is the left fixed end of the sea side No. two rope supporting trolley, the left fixed end is folded back through the left side pulley fixed on the sea side No. one rope supporting trolley, the left fixed end is folded back to the two pulleys fixed at the rear end of the arm support, the right fixed end is folded back to the right fixed end of the sea side No. two rope supporting trolley. Fourth wire rope: the starting position is the left fixed end of the sea side No. two rope supporting trolley land side, the left fixed end is folded back through the left side pulley fixed on the sea side of the main trolley, the left side pulley is folded back to the sea side No. two rope supporting trolley land side, the two pulleys fixed at the rear end of the arm support are rotated, the right side pulley is folded back to the sea side No. two rope supporting trolley land side, the right fixed end is folded back to the right side pulley fixed on the sea side of the main trolley, and the ending position is the right fixed end of the sea side No. two rope supporting trolley land side. Fifth wire rope: the starting position is the left fixed end of the sea side of the first rope supporting trolley on the land side, the left fixed end is folded back through the left side pulley fixed on the land side of the main trolley, the left fixed end is folded back to the left side pulley fixed on the sea side of the first rope supporting trolley on the land side, the two pulleys fixed at the front end of the arm support are rotated, the right fixed end is folded back to the right fixed end fixed on the sea side of the first rope supporting trolley on the land side, and the ending position is the right fixed end of the sea side of the first rope supporting trolley on the land side. Sixth wire rope: the starting position is the left fixed end of the sea side surface of the land side No. two rope supporting trolley, the left fixed end rotates through two pulleys fixed at the front end of the arm support, and the ending position is the right fixed end of the sea side surface of the land side No. two rope supporting trolley.
In the embodiment, two steel wire ropes are respectively rotatably erected at the front end and the rear end of the grab ship unloader arm frame, and 1 rope breakage detection stop block is arranged on each steel wire rope, so that 4 rope breakage detection stop blocks are arranged in total. The two sides of each rope breakage detection stop block are respectively provided with 1 rope breakage detection limit switch, so that 8 rope breakage detection limit switches are arranged in total, and the position of each limit switch corresponds to the working state of one steel wire rope. In this embodiment, the arrangement of the rope rotation position at the front end of the arm support of the grab ship unloader is taken as an example, and the rope breakage detection device consists of a left limit switch, a right limit switch and a detection stop block, wherein the left limit switch and the right limit switch are fixed on the end structure of the arm support, and the detection stop block is fixed on a traction steel wire rope. During normal operation, the traction steel wire ropes at the left side and the right side of the detection stop block are balanced in stress, and the detection stop block is kept in an area between the left limit switch and the right limit switch. If the left traction steel wire rope of the detection check block is broken, the right traction steel wire rope pulls the detection check block to the right, and the right limit switch is triggered, so that the left traction steel wire rope is judged to have a rope breaking fault. Otherwise, if the right traction steel wire rope of the detection check block breaks, the left traction steel wire rope pulls the detection check block to the left to trigger the left limit switch, so that the right traction steel wire rope is judged to break.
Preferably, the grab ship unloader anti-collision subsystem mainly comprises a space positioning unit and a mechanism positioning unit. The space positioning unit is arranged in the tower head area of the grab ship unloader and is used for positioning the whole grab ship unloader. The mechanism positioning unit is arranged in the arm support twisting point, the top of the cab, the machine room and other areas and is sequentially used for realizing the pitching angle positioning of the arm support of the grab ship unloader, the displacement positioning of the cab and the position positioning of the grab. The control unit is positioned in the control room and is used for receiving the data information of the space positioning unit and the mechanism positioning unit, the space position data information of related equipment such as adjacent equipment and ships provided by the wharf central control system, and simultaneously, the data are operated and analyzed, so that the whole anti-collision protection of the grab ship unloader is realized.
In particular, the spatial location unit is composed of an antenna, a data receiver. The mechanism positioning unit consists of an inclinometer, a cab absolute value encoder, a lifting absolute value encoder and a trolley absolute value encoder. The control unit is composed of a PLC controller, an Ethernet communication module and a DP communication module. The space positioning unit is connected with the PLC control unit in an Ethernet communication mode. The mechanism positioning unit is connected with the control unit through Ethernet communication and Profibus DP communication.
As shown in fig. 7a, the space positioning unit is composed of an antenna and a data receiver installed in the tower head area, the Beidou RTK space positioning technology is adopted, the high-precision positioning of the ship unloader mobile station is realized through the differential operation between the wharf base station and the ship unloader mobile station, and the data is transmitted to the control unit through an ethernet protocol. Specifically, in the process, the antenna and the data receiver are used for receiving the position data transmitted by the Beidou RTK positioning system, carrying out differential operation between the wharf base station and the ship unloader mobile station through the Beidou RTK system, obtaining positioning information of the ship unloader mobile station, and directly calling the positioning information in the collision avoidance system.
As shown in fig. 7b, the mechanism positioning unit is composed of an inclinometer, a cab absolute value encoder, a lifting absolute value encoder and a trolley absolute value encoder. The inclinometer is arranged at the arm support twisting point and is used for detecting the pitching operation angle of the arm support, and data of the inclinometer are transmitted to the control unit through a Profibus DP protocol; the cab absolute value encoder is arranged at a wheel at the top of the cab and used for positioning the cab, and data of the cab absolute value encoder are transmitted to the control unit through a Profibus DP protocol; the lifting absolute value encoder and the trolley absolute value encoder are arranged in a machine room and used for lifting and positioning a trolley mechanism, so that the space position of the grab bucket is converted, and data of the grab bucket are transmitted to the PLC control unit through a Profibus DP protocol. The spatial position of the grab bucket is obtained according to the following calculation:
Spatial position of grab in X-axis direction: xgrab=xsul;
wherein XSUL is a cart position value of the grab ship unloader;
spatial position of grab in Y-axis direction: ygrab=l0+ktr etr+btr;
wherein L0 is a horizontal position value from the center of the hopper in the Y-axis direction to the wharf land side track, KTR is a conversion coefficient of a trolley absolute value encoder, ETR is a measured value of the trolley absolute value encoder, and BTR is a correction coefficient of the horizontal position value in the Y-axis direction of the trolley;
spatial position of grab bucket in Z-axis direction: zgrab=kho eho+bho;
wherein KHO is the conversion coefficient of the lifting absolute value encoder, EHO is the measured value of the lifting absolute value encoder, and BHO is the correction coefficient of the lifting height value.
The PLC control unit is used for establishing a space three-dimensional coordinate system and controlling the anti-collision function of the grab ship unloader; the Ethernet communication module is used for receiving data in the space positioning unit and receiving space position data information of related equipment such as adjacent equipment, ships and the like provided by the central control system; the DP communication module is used for receiving data in the mechanism positioning unit. Specifically, the 0 bit in the X direction of the space three-dimensional coordinate system is the position of an equipment anchoring pit, the 0 bit in the Y direction is the position of a land side track, and the 0 bit in the Z direction is the upper surface of a wharf track, and the schematic diagram is shown in fig. 7c.
The invention also provides a control method of the grab ship unloader, which is realized based on the grab ship unloader control system described in any one of the above, as shown in fig. 8, and comprises the following steps:
s1, acquiring a rope breakage detection signal of the lifting opening and closing mechanism based on the control system, and carrying out rope breakage control of the lifting opening and closing mechanism according to the detection signal. The method specifically comprises the following steps:
s101, when an operator operates the grab ship unloader at a cab linkage table, a rope breakage detection function of the lifting opening and closing mechanism is automatically activated.
S102, after receiving a rope breakage detection function activation instruction of the lifting opening and closing mechanism, the PLC control unit sequentially receives, calculates and analyzes detection data of the steel wire rope breakage detection unit and the winding drum running state detection unit. The method specifically comprises the following steps:
s1021, the PLC control unit detects four groups of ultrasonic sensor signals in the wire rope breakage detection unit in real time, and once the signals change, the signals are extracted after the wire rope breakage is judged, and a wire rope breakage fault alarm is immediately sent out to timely interrupt the operation of a corresponding main mechanism.
S1022, the PLC control unit receives real-time data of four groups of RFID detection devices in the steel wire rope state detection unit and four groups of absolute value encoders in the winding drum running state detection unit, converts and compares the data of the four groups of RFID detection devices and the data of the four groups of absolute value encoders, and once the ratio of the running speed of the main pulley fed back by the RFID to the running speed of the winding drum fed back by the absolute value encoder is lower than a set threshold value, the phenomenon that the steel wire rope breaks is judged, a rope breaking fault alarm is immediately sent, and the running of a corresponding main mechanism is timely interrupted. The specific judgment formula is as follows:
Judging formula of normal state of the steel wire rope: k0< (r01×Ω 01)/(r00×Ω 00) <100%;
judging formula of the wire rope breakage state: (R01 x Ω 01)/(R00 x Ω 00) < K0;
wherein R01 is the radius of the main pulley on the trolley, omega 01 is the running angular velocity of the main pulley fed back by the RFID detection device, R00 is the radius of the steel wire rope reel in the machine room, omega 00 is the running angular velocity of the reel detected by the absolute value encoder, K0 is the warning threshold value of the rope breakage fault, and when the calculated ratio is smaller than the warning threshold value of the rope breakage fault, the main pulley is judged to be unable to rotate along with the reel due to the rope breakage fault, and a warning signal of the rope breakage fault is sent.
S103, the main PLC control unit detects in real time by adopting the detection mode in S2 until the ship unloading operation is completed in the operation process of the grab ship unloader, so that the rope breakage detection function of the lifting opening and closing mechanism is realized, and the operation safety and stability of equipment are ensured.
S2, acquiring a traction steel wire rope breakage detection signal based on the control system, and performing traction steel wire rope breakage control according to the detection signal. The method specifically comprises the following steps:
s201, when an operator operates the grab ship unloader at a cab linkage table, the rope breakage detection function of the trolley traction steel wire rope is automatically activated, and after receiving an activation instruction of the rope breakage detection function of the trolley traction steel wire rope, the control unit receives and monitors a limit switch state signal in the rope breakage detection unit of the traction steel wire rope in real time.
S202, in the process of monitoring the state signal of the limit switch in the traction steel wire rope breakage detection unit in real time, once the change of the limit switch signal is found, the control unit judges that the traction steel wire rope breakage causes the limit switch to act, immediately sends out rope breakage fault alarm, and timely interrupts the operation of a corresponding mechanism.
And S203, the control unit synchronously detects the grab ship unloader until the ship unloading operation is completed in the operation process of the grab ship unloader, so that the detection function of rope breakage of the traction steel wire rope of the trolley is realized, and the operation safety and stability of equipment are ensured.
S3, acquiring an anti-collision detection signal of the grab ship unloader based on the control system, and carrying out anti-collision control on the grab ship unloader according to the detection signal. The method specifically comprises the following steps:
s301, when an operator operates the grab ship unloader at the linkage station of the cab to operate, the anti-collision function is automatically activated. At the moment, the whole grab ship unloader positioning information output by the space positioning unit is obtained, a space three-dimensional coordinate system is established based on the whole grab ship unloader positioning information, an X axis of the space three-dimensional coordinate system extends along the horizontal direction of the cart track, a Y axis extends along the horizontal direction of the vertical cart track, and a Z axis extends along the vertical direction.
S302, positioning information of each mechanism of the grab ship unloader is obtained, a grab ship unloader space model is built by combining the actual size of the grab ship unloader, and the grab ship unloader space model is fused into the space three-dimensional coordinate system.
S303, acquiring the spatial position data information of the adjacent equipment and the ship through a wharf central control system and integrating the spatial position data information into the spatial three-dimensional coordinate system.
S304, constructing a collision early warning model based on the grab ship unloader whole machine positioning information, the grab ship unloader space model, adjacent equipment and ship space position data information in the space three-dimensional coordinate system. And when the grab ship unloader operates, collision prompt and action are carried out according to the collision response model, so that the integral anti-collision protection function of the grab ship unloader is realized, and the operation safety and stability of equipment are ensured.
Specifically, the anti-collision protection function between adjacent devices of the ship unloader in the running state of the cart is activated, and the PLC control unit establishes a space model of the ship unloader according to the actual size of the ship unloader and blends the space model into the space three-dimensional coordinate system established in the step two. Meanwhile, the PLC control unit also integrates the spatial position data information of the adjacent equipment provided by the wharf central control system and the positioning data information of each mechanism of the wharf provided by the mechanism positioning unit into the spatial three-dimensional coordinate system. When the cart runs along the X-axis track direction, the PLC control unit monitors and judges collision risk in real time through data in the coordinate system, and timely sends out collision warning and interrupts the running action of the cart.
And (3) activating an anti-collision protection function between the ship unloader and the ship under the running state of the cart, and establishing a grab ship unloader space model by the PLC control unit according to the actual size of the grab ship unloader and merging the grab ship unloader space model into the space three-dimensional coordinate system established in the step (II). Meanwhile, the PLC control unit also integrates the ship space position data information provided by the wharf central control system and the local mechanism positioning data information provided by the mechanism positioning unit into the space three-dimensional coordinate system. When the cart runs along the X-axis track direction, the PLC control unit monitors and judges collision risk in real time through data in the coordinate system, and timely sends out collision warning and interrupts the running action of the cart.
And (3) activating an anti-collision protection function between the ship unloader and the ship and adjacent equipment in the boom pitching descending running state, and enabling the PLC control unit to integrate the space position data information of the ship and the adjacent equipment provided by the wharf central control system and the boom pitching mechanism positioning data information provided by the mechanism positioning unit into the space three-dimensional coordinate system established in the step two. In the pitching descending process of the grab ship unloader arm frame, the PLC control unit monitors and judges collision risks in real time through data in a coordinate system, and timely sends out collision alarms and interrupts pitching descending operation.
And (3) activating an anti-collision protection function between the ship unloader and the ship and adjacent equipment in the running state of the cantilever crane horizontal cab, and merging the space position data information of the ship and the adjacent equipment provided by the wharf central control system and the cab mechanism positioning data information provided by the mechanism positioning unit into the space three-dimensional coordinate system established in the step two. When the grab ship unloader cab moves along the Y axis, the PLC control unit monitors and judges collision risk in real time through data in the coordinate system, and timely sends out collision warning and interrupts operation actions of the cab.
The invention carries out preventive diagnosis and rapid alarm on accidents such as rope breakage, collision and the like of the steel wire rope of the ship unloader, reduces the running risk of equipment, reduces the failure downtime of the equipment, greatly improves the reliability of the equipment, and ensures the running safety, high efficiency and stability of the equipment.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and not for limiting the same; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.
Claims (7)
1. The utility model provides a grab ship unloader control system, sets up on grab ship unloader main part mechanism, its characterized in that includes: the rope breakage detection subsystem comprises a lifting opening and closing mechanism rope breakage detection subsystem and a traction steel wire rope breakage detection subsystem;
the lifting switching mechanism rope breakage detection subsystem is in signal connection with a first detection port of the control system through a bus network and is used for sending a lifting switching mechanism rope breakage detection signal to the control system;
the traction steel wire rope breakage detection subsystem is in signal connection with a second detection port of the control system through a bus network and is used for sending a traction steel wire rope breakage detection signal to the control system;
the grab ship unloader anti-collision subsystem is in signal connection with a third detection port of the control system through a bus network and is used for sending a grab ship unloader anti-collision detection signal to the control system;
the control port of the control system is connected with an executing mechanism of the grab ship unloader and is used for controlling the executing mechanism to act according to the received rope breakage detection signal of the lifting opening and closing mechanism, the rope breakage detection signal of the traction steel wire rope and the anti-collision detection signal of the grab ship unloader;
The lifting switching mechanism rope breakage detection subsystem comprises:
the steel wire rope state detection unit is arranged in the main trolley area of the grab ship unloader and is used for detecting whether the lifting and opening steel wire rope runs in the pulley groove or not and the running rotating speed of a main pulley on the trolley in real time;
the winding drum running state detection unit is arranged at the end part of the lifting and opening-closing winding drum in the machine room and is used for detecting the running rotating speed of the steel wire rope winding drum;
the wire rope state detection unit and the winding drum running state detection unit are respectively connected with a PLC control unit of the control system through buses, and the PLC control unit gives out a rope breakage fault alarm according to state data detected by the wire rope state detection unit and the winding drum running state detection unit and controls the action of the execution unit;
the traction steel wire rope breakage detection subsystem comprises a traction steel wire rope state detection unit which is arranged at the end part of the arm support of the grab ship unloader and in a rear girder area, and the traction steel wire rope state detection unit is used for detecting the running state of a trolley traction steel wire rope in real time and specifically comprises two detection nodes which are arranged at the end part of the arm support of the grab ship unloader and in the rear girder area;
The detection node comprises a limit switch, a communication module, a DI module and a broken rope detection stop block; the method comprises the steps that a rail for running the grab ship unloader trolley is paved on a grab ship unloader arm frame, a sea side rope supporting trolley, a main trolley and a land side rope supporting trolley are sequentially arranged on the rail, a traction steel wire rope is fixed on two sides of the main trolley and is rotationally fixed to the front end and the rear end of the grab ship unloader arm frame respectively through the sea side rope supporting trolley and the land side rope supporting trolley, a rope breakage detection stop block is arranged in the middle of a rotation section of the steel wire rope, limit switches are arranged at two ends of the rotation section, and after the limit switch signals are connected into a DI module, the limit switch signals are sent to a PLC control unit of a control system through a communication module;
in the process of monitoring the state signal of the limit switch in the traction wire rope breakage detection unit in real time, once the change of the limit switch signal is found, the PLC control unit judges that the traction wire rope breakage causes the limit switch to act, immediately sends out a rope breakage fault alarm, and controls the execution unit to act;
the grab ship unloader anticollision subsystem includes:
the space positioning unit is arranged in the tower head area of the grab ship unloader, the space positioning unit obtains the whole machine positioning information of the grab ship unloader based on the Beidou space positioning technology, and the space positioning unit comprises an antenna and a data receiver which are arranged in the tower head area of the grab ship unloader;
The mechanism positioning unit is arranged on each focusing mechanism of the grab ship unloader and used for acquiring positioning information of each mechanism of the grab ship unloader, and comprises an arm support pitching angle positioning device arranged at an arm support twisting point, a cab displacement positioning device arranged at the top of a cab and a grab bucket position positioning device arranged in a machine room;
the PLC control unit establishes a space three-dimensional coordinate system according to the whole machine positioning information of the grab ship unloader, and meanwhile adds the focus mechanism positioning information of the grab ship unloader into the space three-dimensional coordinate system so as to perform collision early warning and control the action of the executing mechanism.
2. The grab ship unloader control system according to claim 1, wherein the steel wire rope state detection unit comprises an ultrasonic sensor, an RFID detection device and a code disc, a communication module, a DI module, a wireless transmission device and a storage battery;
the ultrasonic sensor is arranged at a main pulley rope groove on the main trolley frame and used for detecting whether the lifting and opening-closing steel wire rope runs in the pulley rope groove or not;
the RFID detection device is arranged on the side wall of the main pulley on the main trolley frame, the coding disc of the RFID detection device is arranged around the side wall of the main pulley, and the RFID detection device is used for measuring the rotating speed of the main pulley by reading the data of the coding disc during the rotation process of the main pulley;
The communication module is arranged in an electric cabinet on the main trolley frame and is used for receiving the measured data of the RFID detection device;
the DI module is arranged in an electric cabinet on the main trolley frame and is used for receiving the data of the ultrasonic sensor;
the wireless transmission device is arranged in an electric cabinet on the main trolley frame and is used for realizing data communication with the PLC control unit;
the storage battery is arranged in an electric cabinet on the main trolley frame.
3. The grab ship unloader control system according to claim 1, wherein the arm support pitching angle positioning device is an inclinometer, and is used for detecting an arm support pitching operation angle and sending the arm support pitching operation angle to the PLC controller;
the cab displacement positioning device is a cab absolute value encoder and is used for acquiring cab positioning data and sending the cab positioning data to the PLC;
the grab bucket position positioning device comprises a lifting absolute value encoder and a trolley absolute value encoder, wherein the lifting absolute value encoder is used for acquiring grab bucket lifting data and sending the grab bucket lifting data to the PLC control unit, and the trolley absolute value encoder is used for acquiring trolley mechanism positioning data and sending the trolley mechanism positioning data to the PLC control unit.
4. A grab ship unloader control method, implemented based on the grab ship unloader control system according to any one of claims 1-3, characterized by comprising the steps of:
The control system is used for acquiring a rope breakage detection signal of the lifting opening and closing mechanism and carrying out rope breakage control of the lifting opening and closing mechanism according to the detection signal;
acquiring a traction steel wire rope breakage detection signal based on the control system, and performing traction steel wire rope breakage control according to the detection signal;
and acquiring an anti-collision detection signal of the grab ship unloader based on the control system, and carrying out anti-collision control of the grab ship unloader according to the detection signal.
5. The control method of a grab ship unloader according to claim 4, wherein the control system obtains a rope breakage detection signal of a lifting opening and closing mechanism, and performs rope breakage control of the lifting opening and closing mechanism according to the detection signal, comprising:
the PLC control unit detects four groups of ultrasonic sensor signals in the wire rope breakage detection unit in real time, when any group of ultrasonic sensor signals change, the wire rope is judged to be broken, the wire rope is pulled out, a rope breakage fault alarm is immediately sent out, and the operation of a corresponding main mechanism is timely interrupted;
the PLC control unit receives real-time data of four groups of RFID detection devices in the steel wire rope state detection unit and four groups of absolute value encoders in the winding drum running state detection unit simultaneously, converts and compares the data of the four groups of RFID detection devices and the data of the four groups of absolute value encoders, and once the ratio of the running speed of the main pulley fed back by the RFID to the running speed of the winding drum fed back by the absolute value encoder is lower than a set threshold value, the phenomenon that the steel wire rope breaks is judged, a rope breaking fault alarm is immediately sent out, and the running of a corresponding main mechanism is timely interrupted.
6. The control method of a grab ship unloader according to claim 4, wherein the steps of obtaining a detection signal of rope breakage of the traction wire rope based on the control system, and performing rope breakage control of the traction wire rope based on the detection signal include:
in the process of monitoring the state signal of the limit switch in the traction steel wire rope breakage detection unit in real time, once the change of the limit switch signal is found, the PLC control unit judges that the traction steel wire rope breakage causes the limit switch to act, immediately sends out rope breakage fault warning, and timely interrupts the operation of a corresponding mechanism.
7. The control method of a grab ship unloader according to claim 4, wherein the grab ship unloader collision avoidance detection signal is obtained based on the control system, and the grab ship unloader collision avoidance control is performed according to the detection signal, comprising:
the method comprises the steps that based on the PLC control unit, the whole grab ship unloader positioning information output by the space positioning unit is obtained, a space three-dimensional coordinate system is established based on the whole grab ship unloader positioning information, an X axis of the space three-dimensional coordinate system extends along the horizontal direction of a cart track, a Y axis extends along the horizontal direction of a vertical cart track, and a Z axis extends along the vertical direction;
Based on the PLC control unit, positioning information of each mechanism of the grab ship unloader is obtained, a grab ship unloader space model is built by combining the actual size of the grab ship unloader, and the grab ship unloader space model is fused into the space three-dimensional coordinate system;
acquiring data information of space positions of adjacent equipment and ships through a wharf central control system and integrating the data information into the space three-dimensional coordinate system;
and carrying out collision prompt based on the whole grab ship unloader positioning information, the grab ship unloader space model, the adjacent equipment and the ship space position data information in the space three-dimensional coordinate system, and controlling the action of an executing mechanism.
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